Composite cleaning article and method of manufacturing same



June 28, 1960 2,942,285

` H. Z. GRAY COMPOSITE CLEANING ARTICLE AND METHOD OF MANUFACTURING SAME Filed July 1'7, 1956 IN V EN TOR. HARRY Z. GRAY ATTORNEYS COMPOSITE CLEANING ARTICLE METHOD 4'OFV MANUFACTURING SAME l Harry Z. Gray, Lebanon, Ohio Filed 4July 17, 1956, SELVNO. 598,403 i `7 Claims. (CI. 15-209) The present invention relates to a composite cleaning article and to a method of manufacturing same. More particularly the invention relates to such article having a body of polyurethane foam and a mesh covering of a synthetic fiber or resin, preferably nylon.

Thel article of the invention is primarily intended for use in cleaning vehicle windshields and in household cleaning chores which require the presence of water, a soap or detergent, and an abrasive surface to obtain an effective cleaning action. Such chores include the scrubbing of floors, the cleaning of pots, pans, .charcoal grills, etc. However, the cleaning device is also useful for Y washing walls, cleaning windows, wiping off tables, and

I other such chores requiring only' a mild abrasive action.

It is thereforetan object of the invention `to provide. an article which is satisfactory for use in all cleaning and scrubbing chores which require the presence of water, a soap or detergent, and an abrasive surface.

Another object is to provide such an article in a form which will retain its structural integrity over long periods of use, and which is water-retentive, non-flammable and resistant to soaps, detergents, acids, allcalis, rot, mildew, oils, greases, and most common reagents.

' A -further object is to provide a novel method of manufacturing suchan article.

These and other advantages of the invention will be apparent in view of the following detailed description of the invention when considered with the attached drawing.

In the drawing:

Fig. l is a perspective view, with one corner broken away, showing the form and structure of a cleaning article according to the invention;

Fig. 2 is an exploded view showing the body and mesh covering prior Vto fabrication;

Fig. 3 `is. an enlarged fragmentary section taken through t the edge of the article, substantially as indicated on lines 3--3 of Fig. 1; and

Fig. 4 is an enlarged fragmentary plan view taken substantially as indicated on lines 4-4 of Fig. l.

The novel article, indicated in its entirety by the numeral 10, is shown in a generally rectangular shape. It

will be understood, however, that the invention is not to be limited to thespeciic form shown, but that it may be embodied in square, round or other suitable symmetrical shapes.

The body 12 of the article is formed of the resilient type, as distinguished from the rigid or semi-rigid types, of polyurethane foam by conventional and known techniques. This resilient type of foamhas an' interconnecting cell structure which is water-retentive while retaining high strength. The foam material is readily cut into the desired body shape and is non-#Hammable and resistant to soaps, detergents, acids, alkalis, rot, mildew, oils, greases and most common solvents.

Polyurethane foam materials, as described herein, are also often described as polyester foams, polyester isocyanate foams, isocyanate foams, polyether foams or polyester urethane foams.

The covering 14 of the article is in the form of a` web or mesh of synthetic fiber having regularly spaced and alternating strands 15 and interstices 16 (see Fig. 4). A nylon fiber mesh is preferred because of nylons high tensile strength (65,000 to 114,000 p.s.i. at 21 C. and 65% R.H.), its high retention of strength when wet (85 to 90% of tensile), and its resistance to soaps, detergents,

Y weak acid, alkalis and common solvents. However, other synthetic fibers such as a polyester (Dacron) or an acrylic (Orlon) possessing substantially 4the Same physieals when in mesh form could also be used.

vRefer-ring to Fig. 2, the article 10 as shown in Fig. 1;',is formed by interposing a rectangular foam body 12 between rectangular layers of the synthetic ber mesh covering 14. The composite block of covering-body-covering is then subjected to a fastening operation.

Referring to Fig. 3, the mesh layers are fastened to each other and to the foam body by stitching or sewing preferablyewith nylon or Orlon thread, indicated at 18. The stitching may be done by hand or by a sewing machine, and the thread readily passes through the polyurethane foam without tearing or ripping it. The area of stitching is located inwardly of theedges of the block and causes the sides of the block to assume the curved shape indicated in Figs.. land 3. The stitching also takes place'a suicient distance inwardly of the edges to cause the vformati-on of inwardly directedilange-like portions or ears 19 of the foam material, Iwhich protect and concleal the stitching, and to further-cause the formation of acircumferential bead 20 of foam material which provides means for readily gripping the article.

The composite article l0 is ideally suited for household and other cleaning chores, will present a pleasing appearance and will retain its form over long periods of use. The polyurethane foam body l2 is water-retentive and will no-t crumble when used, as do the natural or cellulose type of sponges after a short period of use. It

, has also been found that the polyurethane foam responds to pressure in a non-linear stress-strain curverwhich is in the shape of an ogive. Thus, while resistant to slight pressures, the foam compresses deeply and suddenly to the bottoming point at higher pressures. This property is extremely valuable when cleaning the interiors of small irregularly shaped objects and it ensures uniform contact of the article 10 at all points with the object being cleaned.

The synthetic fiber mesh covering 14 is sufficiently abrasive that, in the presence of a soap or detergent and Water supplied from the foam body, an effective cleaning action is obtained. However, the mesh covering is sufficiently non-abrasive, far less so than for example, steel wool, that soft surfaces will not be scratched.

While I have illustrated and described a preferred embodiment of my invention, it will be apparent that the invention is not limited thereto, and that changes and modifications may be made therein without departing from the spirit of the invention or from the scope of the subjoined claims.

What is claimed is:

1. A composite cleaning article comprising a poly-Y around the circumference of said article, said bead also' protecting the edges of said layers.

2. A composite cleaning article comprising a substantially rectangular block of polyurethane foam interposed between substantially rectangular layers of a, synthetic fiber covering which provide scrubbing surfaces on the article, said block and -la-yers -being stitched together inwardly of the periphery thereof a suicient distance to allow said foam body to extend beyond the edgesv of said llayers and form -a bead of said -foarn around -the circum- Aference of saidarticle, which bead also protects the edges of said layers.

3. composite cleaning article comprising a substantially rectangular block of 'polyurethane foam interposed between substantially rectangular layers of a nylon mesh :covering which provide scrubbing surfaces on the article, said *block and layers being stitched together inwardly of the periphery thereof -a `suflicient distance to allow said foam body to Lextend beyond `the edges of -said layers and form a bead of -said foam around -the circumference of said `article, which bead also lconceals the edges of said mesh.

l4. A-n article for cleaning purposes comprising, a body o'f-po'lyurethane foam, `abrasivelayers vof a synthetic liber mesh covering opposite sides of said body to provide scrubbing surfaces therefor, and, means for fastening said layers to said body Vinwardly of its edges so that a bead yportion of Vfoam -is formed on said body, which bead por- `t-ion :extends-circumferentially around said article to protect and conceal said fastening Ameans and the edges of said layers.

`5. The method of forming a composite cleaning articlewhch comprises iuterposing a body of polyurethane foam between two layers of a synthetic ,ber mesh -to provide scrubbing Vsurfaces on the article, land stitching said slayers and vfoam together inwardly of the edges thereof a suicient distance to provide a peripheral bead of Vsaid foam which extends beyond the edges of said layers vand conceals said stitching.

6. The method of forming a composite cleaning article which comprises interposing a .body of polyurethane foam between two layers of a nylon mesh covering to provide scrubbing 'surfaces on the article, and securing said layers and foam together inwardly of the edges of the body a suicient distance to provide a peripheral bead of said foam which extends beyond the edges of said layers, conceals said securing means and :provides a hand gripping area on said article.

7. A composite vcleaning .article comprising a body ot polyurethane foam, and an abrasive layer of nylon mesh secured only inwardly of 'its edges to atleast one side of said body ,in vcompact relation thereto to provide a Scrubbing area on said article, said foam being extended beyond the edges of said mesh to provide a bead which protects the edges of said mesh.

References Cited in the rile of this patent UNITED STATES ,PATENTS 423,534 Smith VMar. '18, 1890 2,0%;638 Kingman Ian. 7, 1936 2,052,337 Alefantis Aug. 25, 1936 2,198,164 vHan Apr, 23, 1940 2,804,728 'Polizter ,et al. Sept. 3, 1957 232519.14 M Oss 1.. Y Mar. 11, l1958 FOREIGN PATENTS `1,070,031 France Feb. 17, 1954 Article in Modern Plastics .-dated November 1954, volurne 32-#3 entitled Polyurethane & Polyester Foams, pp. 107 and 1-08. 

1. A COMPOSITE CLEANING ARTICLE COMPRISING A POLYURETHANE FOAM BODY INTERPOSED BETWEEN LAYERS OF A SYNTHETIC FIBER MESH COVERING WHICH PROVIDE BEING FASTENED FACES ON THE ARTICLE, SAID BODY AND LAYERS BEING FASTENED TOGETHER INWARLDY OF THE PERIPHERY THEREOF A SUFFICIENT 